Process for the preparation of unsaturated acids from unsaturated aldehydes

ABSTRACT

Methacrylic acid or acrylic acid are produced by the oxidation of methacrolein or acrolein, respectively, with molecular oxygen in the vapor phase in the presence of a catalytic oxide of molybdenum, phosphorus, arsenic, at least one element selected from the group consisting of U, Ti, Nb, Re, Pb, Zn, and Ga, oxygen, and optionally, at least one of Cu, a rare earth element, Ag, Ta, In, Th, Cd, Tl, alkaline earth metal, NH 4 , Cl, Ni, Al and Ge.

BACKGROUND OF THE INVENTION

A number of catalysts are known to be effective for the oxidation of acrolein or methacrolein to acrylic acid or methacrylic acid, respectively. However, the yields obtained using the catalysts for the preparation of methacrylic acid are low. West German provisional patent No. 2,048,620 discloses catalysts containing the oxides of molybdenum, phosphorus, and arsenic for the oxidation of methacrolein and acrolein to methacrylic acid and acrylic acid, respectively. U.S. Pat. No. 3,761,516 discloses catalysts containing oxides of molybdenum, arsenic and phosphorus on a support, especially Al₂ O₃, having external macropores and a surface not greater than 2 m² /g.

The present invention is a result of a search for more efficient and desirable catalysts for the production of acrylic acid and methacrylic acid. Unexpectedly higher yields of and selectivities to acrylic acid and methacrylic acid are obtained by the vapor phase oxidation of acrolein and methacrolein, respectively, with molecular oxygen in the presence of the new and useful catalysts of the present invention.

SUMMARY OF THE INVENTION

It has been discovered according to the present invention in the process for the preparation of acrylic acid or methacrylic acid by the oxidation of acrolein or methacrolein, respectively, with molecular oxygen in the vapor phase at a reaction temperature of about 200° C to about 500° C in the presence of an oxide catalyst, and optionally in the presence of steam, the improvement comprising

USING AS A CATALYST A CATALYST OF THE FORMULA

    X.sub.a Y.sub.b Mo.sub.12 P.sub.c As.sub.d O.sub.x

wherein

X is at least one element selected from the group consisting of U, Ti, Nb, Re, Pb, Zn, and Ga;

Y is Cu, a rare earth element, Ag, Ta, In, Th, Cd, Tl, an alkaline earth metal, NH₄, Cl, Ni, Al and Ge;

And wherein a is 0.001 to 10;

B IS 0 TO 10;

C IS 0.01 TO 5;

D IS 0.01 TO 5;

X IS THE NUMBER OF OXYGENS REQUIRED TO SATISFY THE VALENCE STATES OF THE OTHER ELEMENTS PRESENT.

The surprisingly advantageous catalysts of this invention give improved yields of acrylic acid and methacrylic acid from acrolein and methacrolein, respectively, in an efficient, convenient, and economical manner at a relatively low temperature.

The most significant aspect of the present invention is the catalyst employed. The catalyst may be any of the catalysts delineated by the above formula. The catalysts can be prepared by a number of different techniques described in the art, such as coprecipitation of soluble salts and calcination of the resulting product.

The catalysts of the invention have preferred limitations on their composition. Preferred are catalysts wherein a is 0.001 to 3, catalysts wherein b is 0.001 to 3; and catalysts wherein b is zero.

Especially preferred are catalysts wherein each of the elements described by X is separately incorporated into the catalyst. This is conveniently accomplished by setting X independently equal to the various elements. Catalysts of particular interest are described wherein Y is at least one element selected from the group consisting of a rare earth element, Al, Ag and Cu.

In the catalyst preparations, the various elements of the catalyst are combined, and the final product is calcined to obtain the catalyst. A number of methods of combining the elements of the catalyst and calcining the resultant product are known to those of skill in the art. In the broad concept of the invention, the particular method of preparing the catalysts is not critical.

There are, however, methods of preparing the catalysts that have been found to be preferred. One preferred preparation involves the preparation of the catalysts in an aqueous slurry or solution of molybdenum, phosphorus and/or arsenic containing components, and adding the remaining components; evaporation of this aqueous mixture; and calcination of the resulting catalysts. Suitable molybdenum compounds that may be employed in the preparation of the catalysts delineated by the above formula include molybdenum trioxide, phosphomolybdic acid, molybdic acid, ammonium heptamolybdate and the like. Suitable phosphorus compounds that may be employed in the preparation of the catalysts include ortho-phosphoric acid, metaphoshoric acid, triphosphoric acid, phosphorus halide or oxyhalide and the like. The remaining components of the catalysts may be added as oxide, acetate, formate, sulfate, nitrate, carbonate, oxyhalide, or halide and the like.

Excellent results are obtained by refluxing phosphoric acid, an arsenic containing compound, and molybdenum trioxide, or ammonium heptamolybdate in water for about one-half hour to 3 hours, however, commercial phosphomolybdic acid may be effectively utilized; adding the remaining components to the aqueous slurry and boiling to a thick paste; drying at 110° C to 120° C in air; and calcining the resulting catalysts.

The calcination of the catalyst usually is accomplished by heating the dry catalytic components at a temperature of about 200° C to about 700° C. The preferred procedure of the invention is wherein the catalyst is calcined at a temperature of 325° C to 425° C.

The reactants of the reaction of the invention are methacrolein or acrolein and oxygen. Molecular oxygen is normally supplied to the reaction in the form of air, but oxygen gas could also be employed. About 0.5 to about 4 moles of oxygen are normally added per mole of methacrolein.

The reaction temperature may vary as different catalysts are employed. Normally, temperature of about 200° C to about 500° C are employed with temperature of 250° C to 370° C being preferred.

The catalyst may be used alone or a support could be employed. Suitable supports include silica, alumina, Alundum, silicon carbide, boron phosphate, zirconia and titania. The catalysts are conveniently used in a fixed-bed reactor using tablets, pellets or the like or in a fluid-bed reactor using a catalyst having a particle size of less than about 300 microns. When a fluid-bed reactor is employed, preferred catalysts are in the form of microspheroidal particles. The contact time may be as low as a fraction of a second or as high as 20 seconds or more. The reaction may be conducted at atmospheric, superatmospheric or subatmospheric pressure, with absolute pressures of about 0.5 to about 4 atmospheres being preferred.

Excellent results are obtained using a coated catalyst consisting essentially of an inert support material having a diameter of at least 20 microns and an outer surface and a continuous coating of said active catalyst on said inert support strongly adhering to the outer surface of said support. The special coated catalyst consists of an inner support material having an outside surface and a coating of the active catalytic material on this outside surface. These catalysts can be prepared by a number of different methods.

The support material for the catalyst forms the inner core of the catalyst. This is an essentially inert support and may have substantially any particle size although a diameter of greater than 20 microns is preferred. Especially preferred in the present invention for use in a commercial reactor are those supports which are spherical and which have a diameter of about 0.2 cm. to about 2 cm. Suitable examples of essentially inert support materials include: Alundum, silica, alumina, alumina-silica, silicon carbide, titania and zirconia. Especially preferred among these supports are Alundum, silica, alumina and alumina silica.

The catalysts may contain essentially any proportions of support and catalytically active material. The limits of this relationship are only set by the relative ability of the catalyst and support material to accommodate each other. Preferred catalysts contain about 10 to about 100 percent by weight of catalytically active material based on the weight of the support.

The preparation of these coated catalysts can be accomplished by various techniques. The basic method of preparing these catalysts is by partially wetting the support material with a liquid and then contacting the support material with a powder of the catalytically active material and gently agitating the mixture until the catalyst is formed. The gentle agitation is most conveniently accomplished by placing the partially wet support in a rotating drum or jar and adding the powdered active catalytic material.

Using the catalysts of the invention in the preparation of methacrylic acid or acrylic acid, excellent yields are obtained in a convenient reaction with low amounts of byproducts.

SPECIFIC EMBODIMENTS COMPARATIVE EXAMPLE A TO D AND EXAMPLES 1 TO 47 Comparison of catalysts containing promoters of invention with base catalyst in the preparation of methacrylic acid

A 20 cc. fixed-bed reactor was constructed of a 1.3 cm. stainless steel tubing. Catalysts prepared as described below were charged to the reactor and heated to the reaction temperature under a flow of air and a feed of methacrolein/ air/nitrogen/steam of 1/5.7/4.6/8.7 was fed over the catalyst at an apparent contact time of 2 to 4 seconds. The reactor was run under the reaction conditions for 1 to 6 hours and the product was collected and analyzed.

COMPARATIVE EXAMPLE A AND EXAMPLES 1 TO 23

The catalysts were prepared as follows:

Comparative Example A 25% Mo₁₂ P₁ As₀.5 O_(x) + 75% Alundum

A solution was prepared consisting of 211.88 grams of ammonium heptamolybdate, (NH₄)₆ Mo₇ O₂₄.4H₂ O, (1.2 mole Mo), 500 mls. distilled water at 60° C and 7.94 grams of ammonium arsenate, NH₄ H₂ AsO₄, (0.05 mole As), as solution in 25 mls. distilled water. A white precipitate formed which was heated to about 100° C for 2 hours. To this mixture was added 11.53 grams of 85% solution phosphoric acid (0.10 mole P). One-half hour later 5.0 grams of hydrazine hydrate was added. The slurry was evaporated to a thick paste, dried overnight in an oven at 110° to 120° C, and ground and screened to less than 80 mesh. This powder was coated on 1/8 inch SA 5223 Alundum balls by taking 50 grams of Alundum, partially wetting the Alundum with 1.8 grams of water and adding 16.7 grams of active catalyst prepared above in five equal portions. During and after each addition, the Alundum was rolled in a glass jar. The powder was evenly coated onto the surface of the Alundum and the final product was dried. A hard uniform material was obtained that consisted of an inner core of the Alundum support with the continuous, strongly adhering coat of the powder on the outside surface of the support. This material was then calcined for 1 hour at 370° C in 40 ml./min. air to form the active catalyst.

EXAMPLE 1 25% U₀.25 Mo₁₂ P₁ As₀.5 O_(x) + 75% Alundum

A solution was prepared consisting of 105.9 grams of ammonium heptamolybdate, (NH₄)₆ Mo₇ O₂₄.4H₂ O, (0.6 mole Mo), 700 mls. of distilled water at 60° C and 4.0 grams of ammonium arsenate, NH₄ H₂ AsO₄, (0.025 mole As) as solution in 25 mls. of water. A white precipitate formed which was heated at 100° C about one-half hour. To this mixture was added 5.3 grams of uranyl acetate (0.0125 mole U), followed by the addition of 5.8 grams of 85% solution phosphoric acid (0.05 mole P). One-half hour later 2.5 grams of hydrazine hydrate were added. The slurry was evaporated to a thick paste, dried overnight in an oven at 110° to 120° C, and ground and screened to less than 80 mesh size. The catalyst was then coated to 25% active level on 1/8 inch SA 5223 Alundum balls. Calcination was the same as in Comparative Example A.

EXAMPLE 2 25% Ti₀.2 Mo₁₂ P₁ As₀.5 O_(x) + 75% Alundum

This catalyst was prepared in the same manner described in Example 1, except 7.72 grams of 20% titanium trichloride solution were employed and hydrazine hydrate was deleted in the catalyst preparation.

EXAMPLE 3 25% (Rare earth mixture)₀.2 Ti₀.1 Mo₁₂ P₁ As₀.5 O_(x) + 75% Alundum

This catalyst was prepared in the same manner described in Example 1, except 3.54 grams of rare earth chloride mixture, 0.5 grams of hydrazine hydrate were employed and 3.85 grams of 20% titanium trichloride solution were added.

EXAMPLES 4 to 19 Preparation of the Catalysts 25% X_(a) Y_(b) Mo₁₂ P₁ As₀.5 O_(x) + 75% Alundum

Various catalysts of the invention were prepared. The catalysts were prepared according to the procedure of Example 1, using 105.9 grams of ammonium molybdate, 700 mls. of 60° C distilled water and 4.0 grams of ammonium arsenate in solution of 25 mls. of water. The catalytic components delineated by X and/or Y were added immediately preceding the addition of 5.8 grams of 85% solution phosphoric acid. 2.5 grams of hydrazine hydrate were added in all preparations, except no hydrazine was added in Examples 8, 10, 12 and 18; 1.0 gram of hydrazine was added in Example 14. To prepare the catalysts, the following compounds and amounts were used:

    ______________________________________                                                                             Amount,                                    Ex.  Element      Compound          g.                                         ______________________________________                                         4    Nb.sub.0.25  niobium chloride  3.37                                       5    Pb.sub.0.25  lead acetate      4.75                                       6    Zn.sub.0.25  zinc acetate      2.75                                       7    Re.sub.0.25  rhenium sesquioxide                                                                              3.03                                       8    Ag.sub.0.1 Ti.sub.0.2                                                                       20% titanium trichloride                                                                         7.72                                                         solution                                                                       silver acetate    0.8                                        9    Ag.sub.0.1 Zn.sub.0.2                                                                       zinc acetate      2.19                                                         silver acetate    0.8                                        10   Nb.sub.0.05 Ti.sub.0.2                                                                      niobium chloride  0.67                                                         20% titanium trichloride                                                       solution          7.72                                       11   Re.sub.0.1 Cu.sub.0.25                                                                      rhenium sesquioxide                                                                              1.21                                                         copper acetate    2.48                                       12   Ti.sub.0.15 Zn.sub.0.1                                                                      20% titanium chloride                                                                            5.78                                                         zinc acetate      1.1                                        13   Zn.sub.0.1   zinc acetate      1.09                                            (rare earth  rare earth chloride mixture                                                                      3.54                                            mixture).sub.0.2                                                                            (Moly Corp. Product                                                            No. 4700)                                                    14   Ti.sub.0.05 Cu.sub.0.05                                                                     20% titanium chloride                                                                            1.92                                            (rare earth  copper acetate    0.50                                            mixture).sub.0.2                                                                            rare earth chloride mixture                                                                      3.54                                       15   Zn.sub.0.05 Cu.sub.0.05                                                                     zinc acetate      0.55                                            (rare earth  copper acetate    0.50                                            mixture).sub.0.2                                                                            rare earth chloride mixture                                                                      3.54                                       16   Ga.sub.0.25  gallium oxide     1.1                                        17   Zn.sub.0.2 Al.sub.0.05 Cu.sub.0.05                                                          zinc acetate      2.19                                                         aluminum chloride 0.6                                                          copper acetate    0.50                                       18   Ti.sub.0.2 Rare earth.sub.0.05                                                              20% titanium chloride                                                                            7.7                                             Cu.sub.0.05  Moly Corp. rare earth                                                          mixture (4700)    0.90                                                         copper acetate    0.50                                       19   Rare earth.sub.0.1 Pb.sub.0.2                                                               lead acetate      3.8                                                          rare earth mixture                                                                               1.77                                       ______________________________________                                    

EXAMPLE 20 25% Mo₁₂ P₁ As₀.5 Nb₀.25 Ag₀.05 O_(x) + 75% Alundum

This catalyst was prepared in the same manner described in Example 1, except that 34.25 grams of ammonium molybdate, 150 mls. water, 1.28 grams of ammonium arsenate, 0.537 grams niobium chloride, 0.134 grams of silver acetate, 1.86 grams of 85% phosphoric acid, and 0.8 grams of hydrazine hydrate were employed.

EXAMPLE 21 25% Mo₁₂ P₁ As₀.5 Nb₀.25 Cu₀.1 O_(x) + 75% Alundum

This catalyst was prepared in the same manner as described in Example 4, except 0.322 grams of copper acetate were added in addition to the niobium chloride.

EXAMPLE 22 25% Zn₀.2 Al₀.08 Cu₀.05 Mo₁₂ P₁.32 As₀.5 O_(x) + 75% Alundum

This catalyst was prepared in the same manner described in Example 17, except that 0.96 grams of aluminum chloride hydrate and 7.6 grams of 85% phosphoric acid were employed.

EXAMPLE 23 25% Re₀.1 Al₀.091 Cu₀.05 Mo₁₂ P₁.32 As₀.5 O_(x) + 75% Alundum

This catalyst was prepared in the same manner described in Example 22, except that 1.1 grams of aluminum chloride hydrate and 1.21 grams of Re₂ O₇ were employed.

COMPARATIVE EXAMPLES B TO D AND EXAMPLES 24 TO 47

The results of the experiments in the oxidation of methacrolein to produce methacrylic acid are shown in the TABLE below. The following definitions are used in measuring the carbon atoms in the feed and the products. ##EQU1## In the same manner described above, catalysts of the invention may be effectively utilized in the preparation of acrylic acid from acrolein.

                                      TABLE                                        __________________________________________________________________________     Performance of Catalysts Containing Promoters of Invention Compared With       Base Catalyst in the Preparation of Methacrylic Acid                                                     Reaction                                                                             Results, %                                     Example                                                                             Catalyst             Temp. ° C                                                                     Methacrylic Acid                                                                        Acetic Acid                                                                           Total Conversion                                                                        Selectivity           __________________________________________________________________________     Comp B                                                                              25% Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75% Alundum                                              326   19.6     0.5    26.0     75.0                  C    25% Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75% Alundum                                              350   43.0     1.9    56.0     76.0                  D    25% Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75% Alundum                                              376   57.0     4.8    83.0     68.0                  24   25% U.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75%                                           329ndum                                                                              61.0     4.8    83.0     73.6                  25   25% Ti.sub.0.2 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75%                                           315ndum                                                                              66.5     5.1    84.0     79.0                  26   25% R.E..sub.0.2 Ti.sub.0.1 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                    356   55.2     7.2    85.5     64.9                       75% Alundum                                                               27   25% Nb.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                                350   50       2.2    59.0     84.0                       75% Alundum                                                               28   25% Nb.sub.0.25 Mo.sub.12 P.sub. 1 As.sub.0.5 O.sub.x                                               376   60.0     2.4    73.0     81.0                       75% Alundum                                                               29   25% Pb.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                                343   65.7     2.8    79.0     83.0                       75% Alundum                                                               30   25% Zn.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                                343   65.3     6.2    90.0     72.0                       75% Alundum                                                               31   25% Re.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                                358   63.1     3.7    80.0     78.0                       75% Alundum                                                               32   25% Ag.sub.0.1 Ti.sub.0.2 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                      334   54.8     6.0    77.7     70.6                       75% Alundum                                                               33   25% Ag.sub.0.1 Zn.sub.0.2 Mo.sub.12 P.sub.1 As.sub.0.05 O.sub.x                                     346   61.3     4.4    79.8     76.7                       75% Alundum                                                               34   25% Ag.sub.0.05 Nb.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                    374   59.3     5.2    83.1     71.4                       75% Alundum                                                               35   25% Ti.sub.0.2 Nb.sub.0.05 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                     344   60.8     6.2    84.8     71.7                       75% Alundum                                                               36   25% Re.sub.0.1 Cu.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                     342   73.4     3.4    88.8     82.6                       75% Alundum                                                               37   25% Ti.sub.0.15 Zn.sub.0.1 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                     347   65.5     4.9    85.1     77.0                       75% Alundum                                                               38   25% R.E..sub.0.2 Zn.sub.0.1 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                    321   61.3     4.0    76.3     80.3                       75% Alundum                                                               39   25% R.E..sub.0.2 Ti.sub.0.05 Cu.sub.0.05 Mo.sub.12 P.sub.1                                          332   62.0     5.0    84.8     73.1                       As.sub.0.5 O.sub.x + 75% Alundum                                          40   25% R.E..sub.0.2 Zn.sub.0.05 Cu.sub.0.05 Mo.sub.12 P.sub.1                                          330   67.2     4.6    84.5     79.5                       As.sub.0.5 O.sub.x + 75% Alundum                                          41   25% Ga.sub.0.25 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75%                                          370ndum                                                                              62.8     4.9    84.5     74.3                  42   25% Zn.sub.0.2 Al.sub.0.05 Cu.sub.0.05 Mo.sub.12 P.sub.1 As.sub.0.5            O.sub.x              327   75.3     4.1    91.8     82                         + 75% Alundum                                                             43   25% Ti.sub.0.2 Rare earth.sub.0.05 Cu.sub.0.05                                                      328   66.9     5.1    89.1     75.1                       Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x + 75% Alundum                        44   25% Nb.sub.0.25 Cu.sub.0.1 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                     346   66.3     7.5    89.8     73.9                       + 75% Alundum                                                             45   25% R.E..sub.0.1 Pb.sub.0.2 Mo.sub.12 P.sub.1 As.sub.0.5 O.sub.x                                    342   59.5     4.8    79.6     74.4                       75% Alundum                                                               46   25% Zn.sub.0.2 Al.sub.0.08 Cu.sub.0.05 Mo.sub.12 P.sub.1.32 As.sub.0.          5                    344   76.1     2.6    90.6     83.8                       O.sub.x + 75% Alundum                                                     47   25% Re.sub.0.1 Al.sub.0.091 Cu.sub.0.05 Mo.sub.12 P.sub.1.32                                        343   69.0     4.1    83.2     82.8                       As.sub.0.5 O.sub.x + 75% Alundum                                          __________________________________________________________________________ 

We claim:
 1. The catalyst composition described by the formula

    X.sub.a Y.sub.b Mo.sub.12 P.sub.c As.sub.d O.sub.x

wherein X is at least one element selected from the group consisting of U, Ti, Nb, Re, Zn, and Ga; Y is at least one element selected from the group consisting of Cu, a rare earth element, Ag, Ta, In, Th, Cd, Tl, NH₄, Cl, Ni, Al and Ge;and wherein a is 0.001 to 10; b is 0 to 10; c is 0.1 to 5; d is 0.01 to 5; x is the number of oxygens required to satisfy the valence states of the other elements present.
 2. The catalyst of claim 1 wherein a is 0.001 to
 3. 3. The catalyst of claim 1 wherein b is 0.001 to
 3. 4. The catalyst of claim 1 wherein b is zero.
 5. The catalyst of claim 1 wherein X is uranium.
 6. The catalyst of claim 1 wherein X is titanium.
 7. The catalyst of claim 1 wherein X is niobium.
 8. The catalyst of claim 1 wherein X is rhenium.
 9. The catalyst of claim 1 wherein X is zinc.
 10. The catalyst of claim 1 wherein X is gallium.
 11. The catalyst of claim 1 wherein X is titanium and niobium.
 12. The catalyst of claim 1 wherein X is titanium and zinc.
 13. The catalyst of claim 1 wherein Y is at least one element selected from the group consisting of Cu, a rare earth element, Al, and Ag.
 14. The catalyst of claim 1 wherein X is rhenium and Y is copper.
 15. The catalyst of claim 1 which is coated on an inert support.
 16. The catalyst of claim 15 consisting essentially of an inert support material having a diameter of at least 20 microns and an outer surface and a continuous coating of said active catalyst strongly adhering to the outer surface of said support.
 17. The catalyst of claim 16 wherein the active catalyst is about 10 to about 100 percent by weight of the inert support.
 18. The catalyst of claim 16 wherein the support is selected from the group consisting of silica, alumina, alumina-silica, silicon carbide, titania and zirconia.
 19. The catalyst of claim 16 wherein the particle size of the inert support is 0.2 cm. to 2 cm. 